Handlebar mould


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AlessandroPA
AlessandroPA
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Hi all, thanks for your support, if somebody can help me I will appreciate.
I've been asked to make carbon handlebars' prototypes for mountain bikes, something like this
It has to be straight and with a bigger central section of 31,8mm and 22mm on the edges for the grips.
Do you think the high density foam is ok to make the mould? 
In this way, I could make the different sections, connect them, sanding and then wrapping everything with the layers of carbon, to have the right width and sections.  In the end, I could pour acetone in to dissolve the foam and getting the final piece.
The boring detail, is that everytime I need to make a handlebar, I should make again another mould, as it will be one-off.
Except using the technique of two halves connected with bolts (not practical for me, as I make moulds with fiberglass and gelcoat), does anybody know another method to build the mould? 
Thanks Smile

Alessandro 
GO

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